Envelope making machine



Jan. 26, 1965 E. c. SAUERMAN ENVELOPE MAKING MACHINE Original Filed Sept. 9, 1960 3 Sheets-Sheet 1 I 121/211 60 r E7251 fiauermam.

GUI/Jew a; v1?

Jan. 26, 1965 E. c. SAUERMAN ENVELOPE MAKING MACHINE 3 Sheets-Sheet 2 Original Filed Sept. 9, 1960 I 121/: I1 for. rw f. Saueriziar;

Jan. 26, 1965 E. c. SAUERMAN ENVELOPE MAKING MACHINE 3 Sheets-Sheet 3 Original Filed Sept. 9, 1960 United States Patent Oihce 3,166,995 Patented Jan. 26, 1965 3,166,996 ENVELGPE MAKlNiG MACHINE Ernst C. Sauerrnan, Chicago, lll., assignor, by niesue assignments, to F. L. rnithe Machine Co., Inc, New

York, N.Y., a corporation of New York Continuation of application Ser. No. 54,942, Sept. 9, 1960.

This application Mar. 5, 1963, Ser. No. 263,679 1 Claim. (Cl. 93-62) This application is a continuation of my copending application for Folding Attachment for Envelope Machines, Serial No. 54,942, filed September 9, 1960, now abancloned.

The present invention relates to an improvement in envelope forming machines and more particularly to a novel attachment therefor for folding the end, side or bottom flap of successive envelope blanks in the production of envelopes including those generally referred to as open end, booklet or wallet styles, and diagonals.

In early prior art envelope forming machines, it has been well known to accomplish the first two of the required four folds of each envelope blank with plowshare folding means while the blank is moving in a first direction and to accomplish the remaining folds, again with plowshare means, after the blank has been stopped and redirected in a new path of travel at 90 to the original direction of travel. A typical envelope forming machine of this type is shown in U.S. Letters Patent No. 1,144,506, issued to E. G. Staude, on June 29, 1915.

While envelope forming machines such as described above had the advantage of employing simple and relatively inexpensive plowshare folding means for making each of the four required folds, they may not be readily speeded up to high production rates. This is because the blank alignment for the second direction of travel may only be obtained by banking a straight unfolded leading edge portion of the blank against a stop means. At high rates of speed, even with large square sided blanks, the unfold leading edge tends to buckle and prevents accu: rate alignment of the blank in the second direction of travel without recourse to' auxiliary alignment means. Furthermore, it is impossible with the above prior art machine to align rhombic envelope blanks with a pointed leading edge for travel in the second direction.

These difliculties, inherent in the arrangement of the Staude patent, supra, fostered the development of high speed envelope making machines wherein all the folds are made while the blank moves in the same general direction after it has been accurately aligned by aligner chains. A machine typical of such arrangement may be seen by reference to US. Letters Patent No. 2,748,675, issued June 5, 1956. Such machines may readily employ plowshare means for accomplishing the first two folds, but of necessity must resort to more complex means, such as buckle plates or the like, for accomplishing the remaining two folds transverse to the direction of travel. While machines of this type were generally suitable for a wide range of envelope flap sizes and shapes, they do not enjoy the simplicity of the prior art slower speed machines.

The present invention combines features of each of the prior art machines in a manner to produce a novel combination wherein three of the desired four folds are made while the blank is travelling in a first direction and where the remaining fourth fold is made with a plowshare folder after the blank has been redirected to a second pathof travel at 90 to the original path. With applicants novel arrangement, accurate alignment of the blank is insured in the second direction, even at high rates.

shape of the blank may have been rhombic, there is no limitation of the machine to folding straight leading edge blanks as in Patent 1,144,506.

Accordingly, it is a principal object to provide a novel attachment for a high speed envelope forming machine which extends its range of usefulness while simplifying its mechanism without reducing the machines permissible speed of operation.

Another object of the present invention is the provision of a novel folding attachment for envelope machines for folding an end, side or back flap of successive envelopes, the attachment being capable of substantially extending the size range of envelopes formed on such machines.

Another important object of the present invention is the provision of a novel buckle plate for automatically folding a flap of successive envelope blanks as each arrives at the buckle plate of the folding station. This novel attachment is susceptible of use on various types of conventional envelope machines and permits the elimination of numerous of the actuating cams and associated mechanism or linkage with which conventional envelope machines are equipped. For example, in Wide range, open side envelope machines the cams and associated linkage for operating the tuckers, pushers and p atters are no longer required with the present invention, thus effecting and assuring substantial savings notonly in the cost of manufacturing of suchprior envelope machines but also in the replacement of parts and servicing thereof as the eliminated mechanisms and their proper functioning are essential to the operation of such prior machines.

The present invention further comprehends a novel buckle plate assembly which automatically folds the end, side or bottom flap of successive envelope blanks without regard to any timed feeding operation for such flap of each blank is automatically folded when reaching the buckle plate in its path of travel.

In the present novel embodiment of folding means,

conventional envelope machines incapable of folding the long or relatively deep bottom flap of an envelope blank can be quickly and easily converted to substantially extend the amount of overlap ofthe back fold or flap and also extend the range of sizes of envelopes being formed.

Another important feature of the present invention is theflprovision of a novel buckle plate assembly which may be easily and quicklyinstalled on various types of envelope machines and readily adjusted to accommodate and fold the end, side or bottom flap of envelope blanks of dilferent types, shapes and sizes.

The present invention further comprehends novel suction means for elevating and directing the scored envelope blanks to the buckle plate whereby feeding, guiding and folding of the scored end, side or bottom flap is most effectively, simply and positively accomplished. While the present invention is shown applied to a conventional machine of the open end type for folding the bottom .or end flap, it will be evident that the invention is not limited thereto but adapted for application to various other types of envelope machines.

Not only does the present novel attachment greatly extend the range of sizes and types of envelopes capable of being folded on conventional envelope machines, as well bly and operation, andsuch further objects, advantages" and capabilities as will later more fully appear and are 3 inherently possessed thereby.

In the drawings:

FIGURE 1 is a view in perspective showing diagrammatically one form of conventional envelope machine in which is embodied the present novel attachment for folding the bottom or end flap of an envelope blank to complete the envelope, and also showing an envelope blank in its various disclosed stages of gumming, scoring and folding.

FIGURE 2 is a view, part in end elevation and part in vertical cross section, of the novel attachment including suction rollers for feeding, lifting and directing the bottom or end flap of successive envelope blanks to be folded and a buckle plate assembly for receiving and folding the flap, the view being taken on the line 2-2 of FIG. 3.

FIGURE 3'is a front elevational view of the assembly of FIG. 2 but including the suction means for intermittently applying suction to the rollers for lifting the flap of successive envelope blanks fed to the novel folding means, the View being taken on the line 3-3 of F IG. 2.

FIGURE 4 is'a fragmentary top plan view of the mechanism for applying suction to the rollers.

FIGURE 5 is a fragmentary view in horizontal cross section taken on the line 5--5 of FIG. 2 and showing in top plan the spaced suction and feed rollers at the opposite sides of the buckle plate assembly.

FIGURE 6 is a view similar to FIG. 2 but showing the bottom or end flap of an envelope blank being lifted by the suction rollers and directed against the stop or abutment on the buckle plate.

FIGURE 7 is a view similar to FIG. 6 but showing a succeeding stage in which the bottom or end flap of the envelope blank has been folded into contact with the gummed side flaps for sealing and completing the envelope which is shown carried on the table by the feed rollers from beneath the lower edge of the buckle plate.

FIGURE 8 is an enlarged view in front elevation of one of the suction rollers on the hollow rotating shaft.

FIGURE 9 is an enlarged view in front elevation of the adjoining disk members for intermittently applying suction to the hollow shaft carrying the suction rollers, one of which disks is held stationary about the rotating shaft and the other is affixed to and rotates with the shaft carrying the suction rollers.

FIGURE 10 is an elevation view of the rotating disk taken on the line 10.-10 of FIG. 9, and with a portion thereof broken away to show the passage through which suction is applied to the shaft and its suction rollers.

FIGURE 11 is an elevational view of the stationary disk taken on the line 1111 of FIG. 9 and with a portion thereof broken away to show the interior including the inlet port and connected passage through which suction is applied to this member.

FIGURE 12 is a view, part in side elevation and part in vertical cross section, of one of the suction rollers with the section showing the internal passage for intermittently applying suction to successive envelope blanks.

.FIGURE 13 is a view in elevation of one side of an envelope blank in which the bottom or end flap is to be folded by means of the novel suction means and buckle plate assembly.

FIGURE 14 ,is a view in elevation of the other side of the envelope blank of FIG. 13.

' FIGURE 15 is a view in elevation of the back of the completely folded envelope.

FIGURE 15a is an elevational view of one side of another form of envelope blank in which both the bottom and the top flaps are folded by successive buckle plates.

FIGURE 16 is a view similar to FIG. 15a but with the bottom flap folded.

FIGURE 17 is a diagrammatic view in end elevation showing the envelope blank of FIG. 16 being fed to a sec- 7 0nd buckle plate assembly for folding the top flap.

Referring to the disclosure in the drawings in which is shown an illustrative embodiment of one form of envelope machine equipped with the novel suction rollers and buckle plate assembly of the present invention. The envelope machine shown diagrammatically in FIG. 1 is of conventional construction having a feeding station 10 from which successive envelope blanks 11 to be formed into envelopes are fed to a conveying means 12 and past a gumming device 13 for applying a strip of a suitable adhesive or gum at 14 to the top flap or closure 15.

The successive blanks with the gummed fiap 15 facing down as in FIG. 13, are carried in an elongated path and dried while carried by the conveying means 12, and deposited onto the top of a table at 16 where the blanks 11 with the gummed portion 14 of the flap 15 facing upwardly as in FIG. 14, are engaged and drawn forwardly by a projection on a roller 17 adapted to move the blanks 11 along the table in properly spaced but partially overlapping relation. Next the successive blanks 11 are passed under spaced rotatable scorers 18, 18 where the side flaps 19, 19 are scored at 21, then the top flap 15 is scored at 23 and the bottom flap 22 is scored at 23" by a rotating transverse scoring blade 24 to form the scored blank 11' of a succeeding stage (FIGS. 1 and 14).

The blank 11* next passes. a gum applicator at 25 which applies gum to the underside of the side flaps 19, 19 after which these flaps are folded inwardly and upwardly by suitable spaced folding means such as inclined folding blades or plowshares at 26 to form the blank 11 (FIG. 1). The structure of the envelope machine so far described is conventional and shown but diagrammatically to form the partially folded envelope blanks 11.

The partially folded blanks 11 in spaced relation are then carried along the table until they are fed beneath and engaged by the transversely spaced draw rollers 27 each of which is preferably covered by rubber or rubberlike material with its hub affixed to a hollow shaft 28. Each of said draw rollers 27 is provided with a radial port29 communicating with the interior of the hollow shaft 28, the latter being journalled for rotation in vertical supports 31 disposed at the opposite sides of the envelope machine.

Encompassing one end of the shaft 28 are two disks or cylindrical members 32 and 33, the disk 32 .being held stationary by suitable means and provided with a port having a nipple 34 (FIGS. 9 and 11) leading from the exterior to the interior of an arcuate recess 35. A relief port 36 is also provided in the disk 32 (FIG. 11). To this nipple is connected a conduit 37 leading into a valve housing 38 having a spring-biased reciprocating valve 39 connected by a conduit 40 to a suction producing means or pump 41.

The valve 39 has a valve stem 42 projecting to the exterior of the housing 38 where its enlarged end 43 is bifurcated to receive'a roller 44 spring-biased into contact with the face of a cam 45 mountal on a cam shaft 46 rotated by a gear 47 keyed to the shaft and in meshing engagement with a drive gear 43 keyed to a drive shaft 49 driven from any suitable power source. has a projection 51 which when it engages the roller 44,

depresses the valve stem 42 and valve 39 to open the valve for applying suction in the conduit 37 opening into the recess 35 of the disk 33. a

The disk or member 33 is keyed or fixed to and rotates with the hollow shaft 28 and is provided with a transverse port 52 (FIG. 10) opening into the interior of the shaft 28 through a radial passage 53. The cylindrical members or disks 32 and 33 are disposed in adjacent relation with their adjoining faces sealed to the atmosphere by a sealing ring 54.

The number and relative spacing of the suction draw rollers 27 which deliver the successive envelope blanks 11 to the novel construction and arrangement of an adjacent buckle plate assembly 55, depends upon the width or transverse dimensions of the envelope blanks delivered thereto and the fold to be made. radial ports 29 of the rollers 27 and the timing of the cam 45 for actuating the suction valve 39 is such that suction The cam 45 g The disposition of the is applied to the hollow shaft 28 and through the ports 29 ofthe draw rollers 27 tothe bottom or end flaps 22 when successive envelope blanks 11 are fed under and carried by these rollers. The flap 22 to be folded of each blank is elevated by suction and directed into contact with the lower surface of an upstanding buckle plate 56 of the assembly 55. This buckle plate 56 is disposed at a rearward inclination to the vertical whereby the leading edge of each flap 22 when lifted against this plate is carried upwardly along the buckle plate until it contacts an abutment or'stop 57 in the form of a transverse barladjustably mounted along its length upon the buckle plat'efand spaced rods or fingers 58 by adjusting screws 59.

The buckle plate 56 has vertically spaced and substantially horizontally extending supporting rods 60 and 60 projecting from the rear of the buckle plate and carried in adjusting blocks 61 and 61 vertically spaced and adjustably mounted on vertical supports or standards 62 anchored at their lower end in an elevated supporting base 63 anchored upon the envelope machine. Each block 61 isanchored in adjusted position by a set screw 64.

Secured to the outer or forward face of the buckle plate 56 are the transversely spaced fingers or rods 58 adjustably mounted in the transverse bar forming the stop 57 and in a vertically spaced and horizontally mounted bar 65 by means of set screws 59. The lower end or edge 67 of the buckle plate 56 projects downwardly to closely adjacent the feed table of the envelope machine, while the depending and curved ends 68 of the laterally spaced fingers or rods 58 extend between the spaced feed and suction-applying rollers 47.

The leading edge of the flap 22 of each envelope blank 11 as it passes beneath the draw rollers 27 is lifted by suction applied through the rolls 27 and this edge is directed against the lower portion of the buckle plate and rides up the inclined face thereof behind the curved portion 68 of the rods 58. As this leading edge reaches the stop or abutment 57 and with each envelope blank 11 continuing its travel by engagement of the rollers 27 therewith even though suction is no longer applied thereto, causes the flap 22 of each blank to buckle along its score line 23 with the folded edge at the score line then becoming the leading edge of the envelope blank Which continues its travel under the lower edge 67 of the buckle plate 56 with the fold being completed as the blank continues its travel beneath spaced draw and pressure applying rollers 69 and an underlying continuous roll 71 for effecting contact and sealing of the bottom flap 22 upon the gummed side flaps 19.

The suction rollers 27 overlie a continuous roll 72 mounted on a drive shaft 73 driven from a power source on the envelope machine. This shaft 73 has keyed thereto a gear 74 in meshing engagement with and driving a gear 75 keyed or secured to the suction shaft 29. The shafts 73 and 29 are journalled in vertical supports '76 at each side of the envelope machine.

The successive envelopes 11 now folded and sealed except for the open top flap 15 continue their travel until engaging an abutment 77 from where they are shown carried by suitable conveying means 78 arranged to deliver the envelopes at a right angle to their previous direction of travel to a deflecting folding blade at 79 for folding the top flap 15, then to a separating means 81 and to a delivery station 82 where they are collected. The top flap 15 remains unsealed for subsequent use of the envelopes.

While the drawings disclose the envelope blanks supplied to the buckle plate assembly by the use of vacuum lifters, the novel buckle plate assembly is susceptible of i under the lower ge sure is applied thereto byth sealing contact between the o tm the gummed side flaps19. i i

As folding of the flap 22 of each envelop automatically accomplished whenever thislflap t e and directed against the buckle plate 56 and arrivesfat its stop 57, accurate timing of the delivery means to the buckle plate is not required as is essential in commercial envelope machines now available or in use. The operator isassured that as each flap to be folded arrives at the buckle plate, folding thereof will be positively effected.

By adjustably mounting the stop or abutment 57, it may be readily adjusted to accomodate the bottom, side or end flaps of different sizes and styles of envelopes.

In FIGS. 15a and 16 are disclosed diagonal envelope blanks 83 in which both the top and bottom end flaps 84 and 85 are folded by means of buckle plates along their score or fold lines 86 and 87, respectively. The bottom flap 85 which forms the leading edge of each advancing envelope blank 83 as shown in FIG. 15a, engages the stop 57 of the previously described buckle plate assembly and is folded in the manner described above.

To fold the top flap 84 by means of a second buckle plate, each partially folded envelope blank 83 (FIG. 16) with its bottom fiap S5 folded and pressed against the previously folded and gummed side flaps 88 and 89, continues in its path and direction of travel with its edge fold at 87 advancing between the bite of an upper draw roller 91 and a lower roller 92 rotating in the direction shown. As each envelope blank 83 then continues its horizontal path of travel, its edge fold at 87 moves over the lower edge of an upwardly inclined buckle plate 93 as shown in FIG. 17 and upwardly between it and spaced overlying fingers 94 until it reaches a transverse stop 95 on the buckle plate 93. This stop is adjustable upwardly or downwardly along the inclined buckle plate to accommodate the top or end flap 84 of envelopes of varying depths or dimensions.

This stop 95 is so positioned as to place or dispose the fold line 86 of successive envelopes in proper position above the bite of the roller 92. and an adjacent roller 95, whereby each envelope blank 83* which is prevented from advancing beyond the stop 95 is folded at the fold line 86 and directed vertically downward between the bite of the rotating rollers 92 and 96 with the fold line 86 then becoming the leading edge and the top flap automatically folded as it passes between these rollers. The completely folded envelopes are then collected in any suitable manner as by means of the spirals or other separating means 81.

It will thus be evident one or both of the opposite end or bottom and top flaps may be successively folded by means of the novel inclined buckle plates. As will be evident from FIG. 17, the inclination of the buckle plate 93 is preferably substantially less than that of the buckle plate 56 so that each envelope blank 83 is automatically directed against and up its inclined surface until reaching the stop 95.

In the commercial or diagonal form of envelope blanks 83 shown in FIGS. 15a and 16, the side fiaps 88 and 89 are gummed after folding thereof has been effected, rather than before as in the form disclosed in FIGS. 1, 13, 14 and 15.

I claim:

An envelope making machine comprising means for conveying horizontally disposed envelope blanks in a first substantially horizontal path, first rotary means located above the conveying means for longitudinally scoring said blanks to form a pair of transverse side flap portions and a body portion therebetween, a rotating blade located above the conveyor means for transversely scoring said blank into a leading bottom flap portion and a trailing seal flap portion separated by said body portion, a pair of transversely separated gum applicators located under- A, a esive to the P fi-ieli of said side flap portions, plowshare dersl o folding means ad acent said eonveylng means and gum iicators for folding said side flap portions upwardly and inwardly over said body portion, buckle plate means for folding said bottom flap portion over the body portion and folded side flap portions, said buckle plate means including; a fiat plate member projecting upwardly above said conveying means, means for adjustably positioning said plate member relative to said conveying means, a plurality of rod-like fingers disposed in substantially parallel spaced relation to said plate member, means securing an upper portion of said fingers to the top of said plate member, an adjustable stop slidably positionable upon said fingers for contacting the forward edge of the bottom flap portion of each envelope blank, and rotary suction means having a radial port for lifting the leading bottom flap portion from the level of the conveying means and directing it into the space between the fingers and the plate member to thereby fold it back upon the body portion as the body and seal fiap portions of the blank continue to advance upon said conveying means, stop means for abutting the just folded leading edge of the blanks and terminating its conveyance in said first path, means for conveying the partially folded blank in a second path at substantially right angles to and co-planar with said first path, plowshare' folding means for folding the seal flap portion over said body portion, and endless belt means arranged substantially parallel to the direction-of the con-- veying means of said first path for receiving and accumulating the folded envelopes.

References Cited in the file of this patent UNITED STATES PATENTS 1,203,904 Otey Nov.7, 1916 1,762,452 Novick June 10, 1930 1,837,769 Fountain Dec. 22, 1931 1,848,448 Weidner Mar. 8, 1932 1,879,990 Oles Sept. 27, 1932 2,281,089 Novick Apr. 28, 1942 2,354,251 Flore July 25, 1944 2,643,594 Sauerman June 20, 1953 2,690,103 Winkler et al Sept. 28, 1954 2,748,675 Atfelder June 5, 1956 2,800,841 Welsh July 30, 1957 FOREIGN PATENTS 512,869 Great Britain Sept. 27, 1939 

